Integrally molded and firmly bonded substrate, without coming off, for container having 3d colored dazzling effect and produced by in-mold injection molding, and manufacturing method of the same

ABSTRACT

An integrally molded and firmly bonded substrate, without coming off, for container having 3D dazzling effect and produced by in-mold injection molding and a manufacturing method of the same are provided, in which aluminum plating operation is conducted on a film to form a reflective film, which is then firmly bonded with a base material, in liquid state having a temperature as high as 150° C.˜300° C., by the high adhesion of the base material produced in liquid state at high temperature, in turn a sheet-material processing operation is conducted. In this manner, adhesive and bonding layer (PET) is not needed for adhesion operation. Not only cost can be reduced but also degumming and peeling will not occur during in-mold injection molding process. Thus, yield rate can be increased and failure rate can be decreased. It can also be recycled for environmental purpose.

BACKGROUND OF INVENTION

1. Field of the Invention

The present invention relates to an integrally molded and firmly bonded substrate, without coming off, for container having 3D colored dazzling effect and produced by in-mold injection molding and a manufacturing method of the same, more particularly to a new design of an integrally molded and firmly bonded substrate, without coming off, for container having 3D colored dazzling effect and produced by in-mold injection molding and a manufacturing method of the same.

2. Brief Description of the Prior Art

In case of containers of in-mold injection molding having 3D pattern variation animation colored dazzling visual effect provided on its surface currently available on the market, electroplating operation is firstly conducted on a polyethylene terephthalate (PET) film so as to form a reflective film, and then a bonding layer with one PET layer thereon is adhered on the reflective film by adhesive and a base material with one polypropylene (PP) layer thereon is adhered to the bonding layer. Next, embossing, varnishing, or printing operations are conducted so as to form a substrate that can be conducted with in-mold injection molding operation in mould so as to produce containers.

The above substrate manufacturing method can achieve expected effect of producing containers having 3D pattern variation animation colored dazzling visual effect. However, it is found in its overall implementation that the reflective film after electroplating is unable to be bonded and integrally molded directly with the base material. Thus, a bonding layer (PET) should be provided between the reflective film and the base material, then the reflective film is adhered to the bonding layer (PET) by adhesive, and the bonding layer (PET) is also adhered to the base material by adhesive. That is to say, two adhesion processes are required between the reflective film and the bonding layer (PET) as well as between the bonding layer (PET) and the base material; hence this will result in higher manufacturing cost. Furthermore, in the process of in-mold injection molding after being disposed in the mould, the substrate will contact with plastic material with high temperature in the mould. As adhesive cannot tolerate high temperature, degumming phenomena is easily produced under high temperature condition. Therefore, intolerability of the adhesive to the high temperature in the mould will cause peeling or detachment between the reflective film and the bonding layer (PET) or between the bonding layer (PET) and the base material, so that the containers thus produced is prone to have defects which is unfavorable to the yield rate of production.

SUMMARY OF THE INVENTION

The main object of the present invention is to provide an integrally molded and firmly bonded substrate, without coming off, for container having 3D colored dazzling effect and produced by in-mold injection molding and a manufacturing method of the same, in which high adhesion of the base material produced in liquid state at high temperature is employed to firmly bond with a reflective film, so that adhesive and bonding layer (PET) is not needed for adhesion operation. Not only cost can be reduced but also degumming and peeling will not occur during in-mold injection molding process. Thus, the yield rate of production can be increased and the failure rate can be decreased.

The main object and effect of the method for manufacturing the integrally molded and firmly bonded substrate, without coming off, for container having 3D colored dazzling effect and produced by in-mold injection molding of the present invention is achieved by the following specific technical means.

The method comprises the following steps of:

(A) conducting electroplating operation on a film so as to form a reflective film thereon;

(B) combining and molding the reflective film with a base material in liquid state having a temperature as high as 250° C.˜300° C., so that high adhesion of the base material generated at high temperature of 250° C.˜300° C. is employed for firmly bonding with the reflective film together;

(C) Sheet-material processing operations are conducted on the substrate integrally formed by the reflective film and the base material so as to accomplish the manufacturing of the substrate having 3D colored dazzling effect patterns thereon.

The main object and effect of the method for manufacturing the integrally molded and firmly bonded container, without coming off, having 3D colored dazzling effect and produced by in-mold injection molding of the present invention is achieved by the following specific technical means.

The method comprises the following steps of:

(A) conducting electroplating operation on a film so as to form a reflective film thereon;

(B) combining and molding the reflective film with a base material in liquid state having a temperature as high as 250° C.˜300° C., so that high adhesion of the base material generated at high temperature of 250° C.˜300° C. is employed for firmly bonding with the reflective film together;

(C) Sheet-material processing operations are conducted on the substrate integrally formed by the reflective film and the base material so as to accomplish the manufacturing of the substrate having 3D colored dazzling effect patterns thereon;

(D) cutting the substrate into desired shape and size;

(E) disposing the substrate thus cut as above in a mould for molding plastic container product;

(F) injecting plastic material in the mould to encapsulate the substrate capable of producing pattern with 3D colored dazzling effect, so as to form a container having surface with 3D colored dazzling effect patterns thereon.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS

FIG. 1 is a schematic view showing the flow chart for manufacturing the substrate of the present invention;

FIG. 2 is a schematic view of the structure of the present invention;

FIG. 3 is a schematic view showing the state of molding of the present invention;

FIG. 4 is a schematic view showing the substrate structure of another embodiment of the present invention;

FIG. 5 is a schematic view showing the flow chart for manufacturing container of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The technical contents, objects and effect of the present invention will become more apparent by the detailed description in conjunction with the accompanying drawings.

Firstly referring to FIGS. 1 and 2, the manufacturing steps comprising:

(A) conducting aluminum electroplating operation on a film made of either polypropylene (PP) or polyethylene terephthalate (PET) so as to form a reflective film (1) thereon;

(B) combining and molding the reflective film (1) with a base material (2) in liquid state having a temperature as high as 250° C.˜300° C. As shown in FIG. 3, the base material (2) can be polyethylene (PE) bonded with foamed or unfoamed polypropylene (PP), ethylene vinyl acetate (EVA) copolymer bonded with foamed or unfoamed polypropylene (PP), polyethylene (PE) mixing with foamed or unfoamed polypropylene (PP), ethylene vinyl acetate (EVA) copolymer mixing with foamed or unfoamed polypropylene (PP), which is heated by a heating device (21) and is pressed with the reflective film (1) together by a roller (22), so that high adhesion of the polyethylene (PE) or ethylene vinyl acetate (EVA) copolymer of the base material (2) generated at high temperature of 250° C.˜300° C. is employed for firmly bonding with the reflective film together;

(C) Sheet-material processing operations are conducted on the substrate integrally formed by the reflective film (1) and the base material (2). The sheet-material processing operations comprise the following steps of: firstly an embossing operation conducted on the reflective film (1) to form bumpy stripes (3) thereon, next a printing operation conducted to form a printing layer (4), and then a varnishing operation conducted to form a protective layer (5). Alternatively, the sheet-material processing operations can comprise the following steps of: a printing operation conducted to form a printing layer (4) firstly, next a varnishing operation conducted to form a protective layer (5), and finally an embossing operation conducted on the reflective film (1) to form bumpy stripes (3) thereon, as shown in FIG. 4. In this manner, the manufacturing of substrate having patterns with 3D colored dazzling effect is accomplished.

Furthermore, the following steps have to be conducted on the substrate thus produced according to above steps, so as to manufacture the container having patterns with 3D colored dazzling effect.

(D) cutting the substrate into desired shape and size;

(E) disposing the substrate thus cut as above in a mould for molding plastic container product;

(F) injecting plastic material in the mould to encapsulate the substrate capable of producing pattern with 3D colored dazzling effect, so as to form a container having its surface with 3D colored dazzling effect pattern thereon.

Based on the foregoing description of the structural constitution and the implementation of the present invention, this invention apparently has the following advantages when comparing with conventional structure.

1. This invention takes advantage of high adhesion of the polyethylene (PE) or ethylene vinyl acetate (EVA) copolymer of the base material generated at high temperature of 250° C.˜300° C. to bond firmly with the reflective film together. Hence, adhesive and bonding layer is not needed for adhesion operation. Thus, overall manufacturing cost can be effectively reduced so as to enhance its competitiveness.

2. As there is no need to use adhesive and bonding layer (PET) in adhesion operation, the substrate is not subject to high temperature to cause degumming or peeling during in-mold injection molding operation. Furthermore, the substrate can firmly bond with plastic material in the mould due to conformity in material or equivalent property. Therefore, the yield rate of manufacturing can be significantly increased and failure rate can be decreased.

3. As there is no need to use adhesive and bonding layer (PET) in adhesion operation, it can conform to environmentally friendly feature. There is no pollution occurred in this invention and hence recycling is possible.

While the present invention has been described by preferred embodiments in conjunction with accompanying drawings, it should be understood that the embodiments and the drawings are merely for descriptive and illustrative purpose, not intended for restriction of the scope of the present invention. Equivalent variations and modifications conducted by person skilled in the art without departing from the spirit and scope of the present invention should be considered to be still within the scope of the present invention. 

What is claimed is:
 1. A method for manufacturing an integrally molded and firmly bonded substrate, without coming off, for container having 3D colored dazzling effect and produced by in-mold injection molding, wherein said method comprises the following steps of: (A) conducting aluminum electroplating operation on a film so as to form a reflective film thereon; (B) combining and molding said reflective film with a base material in liquid state having a temperature as high as 250° C.˜300° C., so that high adhesion of said base material generated at high temperature of 250° C.˜300° C. is employed for firmly bonding with said reflective film together; (C) conducting sheet-material processing operations on said substrate integrally formed by said reflective film and said base material so as to accomplish the manufacturing of said substrate having 3D colored dazzling effect patterns thereon.
 2. The method for manufacturing an integrally molded and firmly bonded substrate, without coming off, for container having 3D colored dazzling effect and produced by in-mold injection molding as claimed in claim 1, wherein said base material is a foamed material.
 3. The method for manufacturing an integrally molded and firmly bonded substrate, without coming off, for container having 3D colored dazzling effect and produced by in-mold injection molding as claimed in claim 1, wherein said film is anyone selected from polypropylene (PP) and polyethylene terephthalate (PET).
 4. The method for manufacturing an integrally molded and firmly bonded substrate, without coming off, for container having 3D colored dazzling effect and produced by in-mold injection molding as claimed in claim 1, wherein said base material is anyone selected from the group containing: polyethylene (PE) bonding with polypropylene (PP), ethylene vinyl acetate (EVA) copolymer bonding with polypropylene (PP), polyethylene (PE) mixing with polypropylene (PP), ethylene vinyl acetate (EVA) copolymer mixing with polypropylene (PP).
 5. The method for manufacturing an integrally molded and firmly bonded substrate, without coming off, for container having 3D colored dazzling effect and produced by in-mold injection molding as claimed in claim 4, wherein said base material is a foamed material.
 6. The method for manufacturing an integrally molded and firmly bonded substrate, without coming off, for container having 3D colored dazzling effect and produced by in-mold injection molding as claimed in claim 1, wherein said sheet-material processing operations comprise the following steps of: firstly an embossing operation conducted on said reflective film to form bumpy stripes thereon, next a printing operation conducted to form a printing layer, and then a varnishing operation conducted to form a protective layer.
 7. The method for manufacturing an integrally molded and firmly bonded substrate, without coming off, for container having 3D colored dazzling effect and produced by in-mold injection molding as claimed in claim 1, wherein said sheet-material processing operations comprise the following steps of: firstly a printing operation conducted to form a printing layer, next a varnishing operation conducted to form a protective layer, and then an embossing operation conducted on said reflective film to form bumpy stripes thereon.
 8. A method for manufacturing an integrally molded and firmly bonded container, without coming off, having 3D colored dazzling effect and produced by in-mold injection molding, wherein said method comprises the following steps of: (A) conducting aluminum electroplating operation on a film so as to form a reflective film thereon; (B) combining and molding said reflective film with a base material in liquid state having a temperature as high as 250° C.-300° C., so that high adhesion of said base material generated at high temperature of 250° C.˜300° C. is employed for firmly bonding with said reflective film together; (C) conducting sheet-material processing operations on said substrate integrally formed by said reflective film and said base material so as to accomplish the manufacturing of said substrate having 3D colored dazzling effect patterns thereon; (D) cutting said substrate into desired shape and size; (E) disposing said substrate thus cut as above in a mould for molding plastic container product; (F) injecting plastic material in the mould to encapsulate said substrate capable of producing patterns with 3D colored dazzling effect, so as to form a container having surface with 3D colored dazzling effect patterns thereon.
 9. The method for manufacturing an integrally molded and firmly bonded container, without coming off, having 3D colored dazzling effect and produced by in-mold injection molding as claimed in claim 8, wherein said base material is a foamed material.
 10. The method for manufacturing an integrally molded and firmly bonded container, without coming off, having 3D colored dazzling effect and produced by in-mold injection molding as claimed in claim 8, wherein said film is anyone selected from polypropylene (PP) and polyethylene terephthalate (PET).
 11. The method for manufacturing an integrally molded and firmly bonded container, without coming off, having 3D colored dazzling effect and produced by in-mold injection molding as claimed in claim 8, wherein said base material is anyone selected from the group containing: polyethylene (PE) bonding with polypropylene (PP), ethylene vinyl acetate (EVA) copolymer bonding with polypropylene (PP), polyethylene (PE) mixing with polypropylene (PP), ethylene vinyl acetate (EVA) copolymer mixing with polypropylene (PP).
 12. The method for manufacturing an integrally molded and firmly bonded container, without coming off, having 3D colored dazzling effect and produced by in-mold injection molding as claimed in claim 11, wherein said base material is a foamed material.
 13. The method for manufacturing an integrally molded and firmly bonded container, without coming off, having 3D colored dazzling effect and produced by in-mold injection molding as claimed in claim 8, wherein said sheet-material processing operations comprise the following steps of: an embossing operation conducted on said reflective film firstly to form bumpy stripes thereon, next a printing operation conducted to form a printing layer, and then a varnishing operation conducted to form a protective layer.
 14. The method for manufacturing an integrally molded and firmly bonded container, without coming off, having 3D colored dazzling effect and produced by in-mold injection molding as claimed in claim 8, wherein said sheet-material processing operations comprise the following steps of: firstly a printing operation conducted to form a printing layer, next a varnishing operation conducted to form a protective layer, and then an embossing operation conducted on said reflective film to form bumpy stripes thereon. 